Dynamic Optical Assembly For Laser-Based Additive Manufacturing

ABSTRACT

A method and an apparatus of a powder bed fusion additive manufacturing system that enables a quick change in the optical beam delivery size and intensity across locations of a print surface for different powdered materials while ensuring high availability of the system. A dynamic optical assembly containing a set of lens assemblies of different magnification ratios and a mechanical assembly may change the magnification ratios as needed. The dynamic optical assembly may include a transitional and rotational position control of the optics to minimize variations of the optical beam sizes across the print surface.

CROSS REFERENCE TO RELATED PATENT APPLICATION

This application is a continuation of U.S. patent application Ser. No.15/337,610, filed Oct. 28, 2016, which claims the priority benefit of:

U.S. Patent Application No. 62/248,758, filed on Oct. 30, 2015,

U.S. Patent Application No. 62/248,765, filed on Oct. 30, 2015,

U.S. Patent Application No. 62/248,770, filed on Oct. 30, 2015,

U.S. Patent Application No. 62/248,776, filed on Oct. 30, 2015,

U.S. Patent Application No. 62/248,783, filed on Oct. 30, 2015,

U.S. Patent Application No. 62/248,791, filed on Oct. 30, 2015,

U.S. Patent Application No. 62/248,799, filed on Oct. 30, 2015,

U.S. Patent Application No. 62/248,966, filed on Oct. 30, 2015,

U.S. Patent Application No. 62/248,968, filed on Oct. 30, 2015,

U.S. Patent Application No. 62/248,969, filed on Oct. 30, 2015,

U.S. Patent Application No. 62/248,980, filed on Oct. 30, 2015,

U.S. Patent Application No. 62/248,989, filed on Oct. 30, 2015,

U.S. Patent Application No. 62/248,780, filed on Oct. 30, 2015,

U.S. Patent Application No. 62/248,787, filed on Oct. 30, 2015,

U.S. Patent Application No. 62/248,795, filed on Oct. 30, 2015,

U.S. Patent Application No. 62/248,821, filed on Oct. 30, 2015,

U.S. Patent Application No. 62/248,829, filed on Oct. 30, 2015,

U.S. Patent Application No. 62/248,833, filed on Oct. 30, 2015,

U.S. Patent Application No. 62/248,835, filed on Oct. 30, 2015,

U.S. Patent Application No. 62/248,839, filed on Oct. 30, 2015,

U.S. Patent Application No. 62/248,841, filed on Oct. 30, 2015,

U.S. Patent Application No. 62/248,847, filed on Oct. 30, 2015, and

U.S. Patent Application No. 62/248,848, filed on Oct. 30, 2015, whichare incorporated by reference in their entirety.

TECHNICAL FIELD

The present disclosure generally relates to a dynamic optical assemblysuitable for a hot or cold swap of imaging lenses capable ofhigh-resolution imaging of an additive print job, more particularly, tocontrol the magnification ratio and image plane location over a printsurface for the print job.

BACKGROUND

In powder bed fusion additive manufacturing, a source image of anoptical beam of sufficient energy is directed to locations on the topsurface of a powder bed (print surface) to form an integral object whena powdered material is processed (with or without chemical bonding). Theresolution (or a pixel size) of an optical system used for powder bedfusion additive manufacturing depends on whether the print surfacecoincides with the focal plane of the final optics in the opticalsystem, or in term for imaging systems, depending on whether thedistance between lenses and image planes for optics performing animaging operation stays substantially a constant distance for a givenlens configuration. To be able to print large objects in powder bedfusion additive manufacturing, accurate control of the image location onthe print surface, and distance between lenses is necessary to maintainthe resolution or the pixel size on every possible location of the topsurface of the powder bed. Different powdered materials may requiredifferent intensities or energies of the optical beam as the respectivethresholds of bonding energies are different. If a change in theintensity is required when changing the powder type or the powder sizedistribution, the optical system may need to be shut down forre-installation and re-alignment of the imaging lenses.

BRIEF DESCRIPTION OF THE DRAWINGS

Non-limiting and non-exhaustive embodiments of the present disclosureare described with reference to the following figures, wherein likereference numerals refer to like parts throughout the various figuresunless otherwise specified.

FIG. 1A illustrates an additive manufacturing system;

FIG. 1B is a top view of a structure being formed on an additivemanufacturing system;

FIG. 2 illustrates an additive manufacturing method;

FIG. 3A is a cartoon illustrating an additive manufacturing systemincluding lasers;

FIG. 3B is a detailed description of the light patterning unit shown inFIG. 3A;

FIG. 3C is one embodiment of an additive manufacturing system with a“switchyard” for directing and repatterning light using multiple imagerelays;

FIG. 3D illustrates a simple mirror image pixel remapping;

FIG. 3E illustrates a series of image transforming image relays forpixel remapping;

FIG. 3F illustrates an patternable electron energy beam additivemanufacturing system;

FIG. 3G illustrates a detailed description of the electron beampatterning unit shown in FIG. 3F.

FIG. 4 is a block diagram depicting an example apparatus of a dynamicoptical assembly capable of configuring a magnification ratio inaccordance with an embodiment of the present disclosure.

FIG. 5 is an example implementation of a lens assembly for a 4×de-magnification in accordance with an embodiment of the presentdisclosure.

FIG. 6 is another example implementation of a lens assembly for a 25×de-magnification in accordance with an embodiment of the presentdisclosure.

FIG. 7 is another example implementation of a lens assembly for a 4×magnification in accordance with an embodiment of the presentdisclosure.

FIG. 8 is an example implementation of a mechanical assembly containinga set of lens assemblies in accordance with an embodiment of the presentdisclosure.

FIG. 9 is a diagram illustrating a swap of second sets of optical lensesin respective lens assemblies in accordance with an embodiment of thepresent disclosure.

FIG. 10 is another diagram illustrating a swap of second sets of opticallenses in respective lens assemblies in accordance with an embodiment ofthe present disclosure.

FIG. 11 is a diagram illustrating a removal of a second set of opticallenses in a respective lens assembly in accordance with an embodiment ofthe present disclosure.

FIG. 12 is a block diagram depicting another example apparatus of adynamic optical assembly capable of controlling an image distance inaccordance with an embodiment of the present disclosure.

FIG. 13 is an example implementation of a dynamic optical assemblycapable of controlling an image distance in accordance with anembodiment of the present disclosure.

FIG. 14 is another example implementation of a dynamic optical assemblycapable of controlling an image distance in accordance with anembodiment of the present disclosure.

FIG. 15 is another example implementation of a dynamic optical assemblycapable of controlling an image distance in accordance with anembodiment of the present disclosure.

FIG. 16 is another example implementation of a dynamic optical assemblycapable of controlling an image distance in accordance with anembodiment of the present disclosure.

FIG. 17 is a block diagram illustrating process steps of performing alaser-based powder bed fusion additive print job in accordance with anembodiment of the present disclosure.

FIG. 18 is an example implementation of a dynamic optical assemblycapable of selecting a magnification ratio and controlling an imagedistance in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION

In the following description, reference is made to the accompanyingdrawings that form a part thereof, and in which is shown by way ofillustrating specific exemplary embodiments in which the disclosure maybe practiced. These embodiments are described in sufficient detail toenable those skilled in the art to practice the concepts disclosedherein, and it is to be understood that modifications to the variousdisclosed embodiments may be made, and other embodiments may beutilized, without departing from the scope of the present disclosure.The following detailed description is, therefore, not to be taken in alimiting sense.

The present disclosure describes a dynamic optical assembly in a powderbed fusion additive three-dimensional manufacturing system suitable foron-the-fly swapping of imaging lens(es) and high-resolution imaging ofhigh average power light sources in forming a large three-dimensionalobject. Swapping can include both physically replacing, or themodification of a lens such that it has the effect of being a differentlens.

In various embodiments in accordance with the present disclosure, adynamic optical assembly may allow swapping of imaging lens without theneed to disassemble the optical assembly to enable differentmagnification ratios between the source image plane and locations on thetop surface of a powder bed. Different magnification ratios entail thatthe same amount of laser power is distributed over different areas, thespecific degree of which may be tuned according to different materialtypes. In some embodiments, the same optical beam may be used fordifferent chambers containing different powdered materials, the dynamicoptical assembly of the present disclosure may deliver an appropriatepower flux to each chamber while fully utilizing the power capabilitiesof the light source.

An additive manufacturing system is disclosed which has one or moreenergy sources, including in one embodiment, one or more laser orelectron beams, positioned to emit one or more energy beams. Beamshaping optics may receive the one or more energy beams from the energysource and form a single beam. An energy patterning unit receives orgenerates the single beam and transfers a two-dimensional pattern to thebeam, and may reject the unused energy not in the pattern. An imagerelay receives the two-dimensional patterned beam and focuses it as atwo-dimensional image to a desired location on a height fixed or movablebuild platform (e.g. a powder bed). In certain embodiments, some or allof any rejected energy from the energy patterning unit is reused.

In some embodiments, multiple beams from the laser array(s) are combinedusing a beam homogenizer. This combined beam can be directed at anenergy patterning unit that includes either a transmissive or reflectivepixel addressable light valve. In one embodiment, the pixel addressablelight valve includes both a liquid crystal module having a polarizingelement and a light projection unit providing a two-dimensional inputpattern. The two-dimensional image focused by the image relay can besequentially directed toward multiple locations on a powder bed to builda 3D structure.

As seen in FIG. 1, an additive manufacturing system 100 has an energypatterning system 110 with an energy source 112 that can direct one ormore continuous or intermittent energy beam(s) toward beam shapingoptics 114. After shaping, if necessary, the beam is patterned by anenergy patterning unit 116, with generally some energy being directed toa rejected energy handling unit 118. Patterned energy is relayed byimage relay 120 toward an article processing unit 140, typically as atwo-dimensional image 122 focused near a bed 146. The bed 146 (withoptional walls 148) can form a chamber containing material 144 dispensedby material dispenser 142. Patterned energy, directed by the image relay120, can melt, fuse, sinter, amalgamate, change crystal structure,influence stress patterns, or otherwise chemically or physically modifythe dispensed material 144 to form structures with desired properties.

Energy source 112 generates photon (light), electron, ion, or othersuitable energy beams or fluxes capable of being directed, shaped, andpatterned. Multiple energy sources can be used in combination. Theenergy source 112 can include lasers, incandescent light, concentratedsolar, other light sources, electron beams, or ion beams. Possible lasertypes include, but are not limited to: Gas Lasers, Chemical Lasers, DyeLasers, Metal Vapor Lasers, Solid State Lasers (e.g. fiber),Semiconductor (e.g. diode) Lasers, Free electron laser, Gas dynamiclaser, “Nickel-like” Samarium laser, Raman laser, or Nuclear pumpedlaser.

A Gas Laser can include lasers such as a Helium—neon laser, Argon laser,Krypton laser, Xenon ion laser, Nitrogen laser, Carbon dioxide laser,Carbon monoxide laser or Excimer laser.

A Chemical laser can include lasers such as a Hydrogen fluoride laser,Deuterium fluoride laser, COIL (Chemical oxygen-iodine laser), or Agil(All gas-phase iodine laser).

A Metal Vapor Laser can include lasers such as a Helium-cadmium (HeCd)metal-vapor laser, Helium-mercury (HeHg) metal-vapor laser,Helium-selenium (HeSe) metal-vapor laser, Helium-silver (HeAg)metal-vapor laser, Strontium Vapor Laser, Neon-copper (NeCu) metal-vaporlaser, Copper vapor laser, Gold vapor laser, or Manganese (Mn/MnCl₂)vapor laser.

A Solid State Laser can include lasers such as a Ruby laser, Nd:YAGlaser, NdCrYAG laser, Er:YAG laser, Neodymium YLF (Nd:YLF) solid-statelaser, Neodymium doped Yttrium orthovanadate(Nd:YVO₄) laser, Neodymiumdoped yttrium calcium oxoborateNd:YCa₄O(BO₃)³ or simply Nd:YCOB,Neodymium glass(Nd:Glass) laser, Titanium sapphire(Ti:sapphire) laser,Thulium YAG (Tm:YAG) laser, Ytterbium YAG (Yb:YAG) laser, Ytterbium:2O₃(glass or ceramics) laser, Ytterbium doped glass laser (rod, plate/chip,and fiber), Holmium YAG (Ho:YAG) laser, Chromium ZnSe (Cr:ZnSe) laser,Cerium doped lithium strontium (or calcium)aluminum fluoride(Ce:LiSAF,Ce:LiCAF), Promethium 147 doped phosphate glass(147Pm⁺³:Glass)solid-state laser, Chromium doped chrysoberyl (alexandrite) laser,Erbium doped anderbium-ytterbium co-doped glass lasers, Trivalenturanium doped calcium fluoride (U:CaF₂) solid-state laser, Divalentsamarium doped calcium fluoride(Sm:CaF₂) laser, or F-Center laser.

A Semiconductor Laser can include laser medium types such as GaN, InGaN,AlGaInP, AlGaAs, InGaAsP, GaInP, InGaAs, InGaAsO, GaInAsSb, lead salt,Vertical cavity surface emitting laser (VCSEL), Quantum cascade laser,Hybrid silicon laser, or combinations thereof.

For example, in one embodiment a single Nd:YAG q-switched laser can beused in conjunction with multiple semiconductor lasers. In anotherembodiment, an electron beam can be used in conjunction with anultraviolet semiconductor laser array. In still other embodiments, atwo-dimensional array of lasers can be used. In some embodiments withmultiple energy sources, pre-patterning of an energy beam can be done byselectively activating and deactivating energy sources.

Beam shaping unit 114 can include a great variety of imaging optics tocombine, focus, diverge, reflect, refract, homogenize, adjust intensity,adjust frequency, or otherwise shape and direct one or more energy beamsreceived from the energy source 112 toward the energy patterning unit116. In one embodiment, multiple light beams, each having a distinctlight wavelength, can be combined using wavelength selective mirrors(e.g. dichroics) or diffractive elements. In other embodiments, multiplebeams can be homogenized or combined using multifaceted mirrors,microlenses, and refractive or diffractive optical elements.

Energy patterning unit 116 can include static or dynamic energypatterning elements. For example, photon, electron, or ion beams can beblocked by masks with fixed or movable elements. To increase flexibilityand ease of image patterning, pixel addressable masking, imagegeneration, or transmission can be used. In some embodiments, the energypatterning unit includes addressable light valves, alone or inconjunction with other patterning mechanisms to provide patterning. Thelight valves can be transmissive, reflective, or use a combination oftransmissive and reflective elements. Patterns can be dynamicallymodified using electrical or optical addressing. In one embodiment, atransmissive optically addressed light valve acts to rotate polarizationof light passing through the valve, with optically addressed pixelsforming patterns defined by a light projection source. In anotherembodiment, a reflective optically addressed light valve includes awrite beam for modifying polarization of a read beam. In yet anotherembodiment, an electron patterning device receives an address patternfrom an electrical or photon stimulation source and generates apatterned emission of electrons.

Rejected energy handling unit 118 is used to disperse, redirect, orutilize energy not patterned and passed through the energy pattern imagerelay 120. In one embodiment, the rejected energy handling unit 118 caninclude passive or active cooling elements that remove heat from theenergy patterning unit 116. In other embodiments, the rejected energyhandling unit can include a “beam dump” to absorb and convert to heatany beam energy not used in defining the energy pattern. In still otherembodiments, rejected beam energy can be recycled using beam shapingoptics 114. Alternatively, or in addition, rejected beam energy can bedirected to the article processing unit 140 for heating or furtherpatterning. In certain embodiments, rejected beam energy can be directedto additional energy patterning systems or article processing units.

Image relay 120 receives a patterned image (typically two-dimensional)from the energy patterning unit 116 and guides it toward the articleprocessing unit 140. In a manner similar to beam shaping optics 114, theimage relay 120 can include optics to combine, focus, diverge, reflect,refract, adjust intensity, adjust frequency, or otherwise shape anddirect the patterned image.

Article processing unit 140 can include a walled chamber 148 and bed144, and a material dispenser 142 for distributing material. Thematerial dispenser 142 can distribute, remove, mix, provide gradationsor changes in material type or particle size, or adjust layer thicknessof material. The material can include metal, ceramic, glass, polymericpowders, other melt-able material capable of undergoing a thermallyinduced phase change from solid to liquid and back again, orcombinations thereof. The material can further include composites ofmelt-able material and non-melt-able material where either or bothcomponents can be selectively targeted by the imaging relay system tomelt the component that is melt-able, while either leaving along thenon-melt-able material or causing it to undergo avaporizing/destroying/combusting or otherwise destructive process. Incertain embodiments, slurries, sprays, coatings, wires, strips, orsheets of materials can be used. Unwanted material can be removed fordisposable or recycling by use of blowers, vacuum systems, sweeping,vibrating, shaking, tipping, or inversion of the bed 146.

In addition to material handling components, the article processing unit140 can include components for holding and supporting 3D structures,mechanisms for heating or cooling the chamber, auxiliary or supportingoptics, and sensors and control mechanisms for monitoring or adjustingmaterial or environmental conditions. The article processing unit can,in whole or in part, support a vacuum or inert gas atmosphere to reduceunwanted chemical interactions as well as to mitigate the risks of fireor explosion (especially with reactive metals).

Control processor 150 can be connected to control any components ofadditive manufacturing system 100. The control processor 150 can beconnected to variety of sensors, actuators, heating or cooling systems,monitors, and controllers to coordinate operation. A wide range ofsensors, including imagers, light intensity monitors, thermal, pressure,or gas sensors can be used to provide information used in control ormonitoring. The control processor can be a single central controller, oralternatively, can include one or more independent control systems. Thecontroller processor 150 is provided with an interface to allow input ofmanufacturing instructions. Use of a wide range of sensors allowsvarious feedback control mechanisms that improve quality, manufacturingthroughput, and energy efficiency.

FIG. 1B is a cartoon illustrating a bed 146 that supports material 144.Using a series of sequentially applied, two-dimensional patterned energybeam images (squares in dotted outline 124), a structure 149 isadditively manufactured. As will be understood, image patterns havingnon-square boundaries can be used, overlapping or interpenetratingimages can be used, and images can be provided by two or more energypatterning systems. In other embodiments, images can be formed inconjunction with directed electron or ion beams, or with printed orselective spray systems.

FIG. 2 is a flow chart illustrating one embodiment of an additivemanufacturing process supported by the described optical and mechanicalcomponents. In step 202, material is positioned in a bed, chamber, orother suitable support. The material can be a powder capable of beingmelted, fused, sintered, induced to change crystal structure, havestress patterns influenced, or otherwise chemically or physicallymodified to form structures with desired properties.

In step 204, unpatterned energy is emitted by one or more energyemitters, including but not limited to solid state or semiconductorlasers, or electrical power supply flowing electrons down a wire. Instep 206, the unpatterned energy is shaped and modified (e.g. intensitymodulated or focused). In step 208, this unpatterned energy ispatterned, with energy not forming a part of the pattern being handledin step 210 (this can include conversion to waste heat, or recycling aspatterned or unpatterned energy). In step 212, the patterned energy, nowforming a two-dimensional image is relayed toward the material. In step214, the image is applied to the material, building a portion of a 3Dstructure. These steps can be repeated (loop 218) until the image (ordifferent and subsequent image) has been applied to all necessaryregions of a top layer of the material. When application of energy tothe top layer of the material is finished, a new layer can be applied(loop 216) to continue building the 3D structure. These process loopsare continued until the 3D structure is complete, when remaining excessmaterial can be removed or recycled.

FIG. 3A is one embodiment of an additive manufacturing system 300 thatuses multiple semiconductor lasers as part of an energy patterningsystem 310. A control processor 350 can be connected to variety ofsensors, actuators, heating or cooling systems, monitors, andcontrollers to coordinate operation of multiple lasers 312, lightpatterning unit 316, and image relay 320, as well as any other componentof system 300. These connections are generally indicated by a dottedoutline 351 surrounding components of system 300. As will beappreciated, connections can be wired or wireless, continuous orintermittent, and include capability for feedback (for example, thermalheating can be adjusted in response to sensed temperature). The multiplelasers 312 can emit a beam 301 of light at a 1000 nm wavelength that,for example, is 90 mm wide by 20 mm tall. The beam 301 is resized byimaging optics 370 to create beam 303. Beam 303 is 6 mm wide by 6 mmtall, and is incident on light homogenization device 372 which blendslight together to create blended beam 305. Beam 305 is then incident onimaging assembly 374 which reshapes the light into beam 307 and is thenincident on hot cold mirror 376. The mirror 376 allows 1000 nm light topass, but reflects 450 nm light. A light projector 378 capable ofprojecting low power light at 1080p pixel resolution and 450 nm emitsbeam 309, which is then incident on hot cold mirror 376. Beams 307 and309 overlay in beam 311, and both are imaged onto optically addressedlight valve 380 in a 20 mm wide, 20 mm tall image. Images formed fromthe homogenizer 372 and the projector 378 are recreated and overlaid onlight valve 380.

The optically addressed light valve 380 is stimulated by the light(typically ranging from 400-500 nm) and imprints a polarization rotationpattern in transmitted beam 313 which is incident upon polarizer 382.The polarizer 382 splits the two polarization states, transmittingp-polarization into beam 317 and reflecting s-polarization into beam 315which is then sent to a beam dump 318 that handles the rejected energy.As will be understood, in other embodiments the polarization could bereversed, with s-polarization formed into beam 317 and reflectingp-polarization into beam 315. Beam 317 enters the final imaging assembly320 which includes optics 384 that resize the patterned light. This beamreflects off of a movable mirror 386 to beam 319, which terminates in afocused image applied to material bed 344 in an article processing unit340. The depth of field in the image selected to span multiple layers,providing optimum focus in the range of a few layers of error or offset.

The bed 390 can be raised or lowered (vertically indexed) within chamberwalls 388 that contain material 344 dispensed by material dispenser 342.In certain embodiments, the bed 390 can remain fixed, and optics of thefinal imaging assembly 320 can be vertically raised or lowered. Materialdistribution is provided by a sweeper mechanism 392 that can evenlyspread powder held in hopper 394, being able to provide new layers ofmaterial as needed. An image 6 mm wide by 6 mm tall can be sequentiallydirected by the movable mirror 386 at different positions of the bed.

When using a powdered ceramic or metal material in this additivemanufacturing system 300, the powder can be spread in a thin layer,approximately 1-3 particles thick, on top of a base substrate (andsubsequent layers) as the part is built. When the powder is melted,sintered, or fused by a patterned beam 319, it bonds to the underlyinglayer, creating a solid structure. The patterned beam 319 can beoperated in a pulsed fashion at 40 Hz, moving to the subsequent 6 mm×6mm image locations at intervals of 10 ms to 0.5 ms (with 3 to 0.1 msbeing desirable) until the selected patterned areas of powder have beenmelted. The bed 390 then lowers itself by a thickness corresponding toone layer, and the sweeper mechanism 392 spreads a new layer of powderedmaterial. This process is repeated until the 2D layers have built up thedesired 3D structure. In certain embodiments, the article processingunit 340 can have a controlled atmosphere. This allows reactivematerials to be manufactured in an inert gas, or vacuum environmentwithout the risk of oxidation or chemical reaction, or fire or explosion(if reactive metals are used).

FIG. 3B illustrates in more detail operation of the light patterningunit 316 of FIG. 3A. As seen in FIG. 3B, a representative input pattern333 (here seen as the numeral “9”) is defined in an 8×12 pixel array oflight projected as beam 309 toward mirror 376. Each grey pixelrepresents a light filled pixel, while white pixels are unlit. Inpractice, each pixel can have varying levels of light, includinglight-free, partial light intensity, or maximal light intensity.Unpatterned light 331 that forms beam 307 is directed and passes througha hot/cold mirror 376, where it combines with patterned beam 309. Afterreflection by the hot/cold mirror 376, the patterned light beam 311formed from overlay of beams 307 and 309 in beam 311, and both areimaged onto optically addressed light valve 380. The optically addressedlight valve 380, which would rotate the polarization state ofunpatterned light 331, is stimulated by the patterned light beam 309,311 to selectively not rotate the polarization state of polarized light307, 311 in the pattern of the numeral “9” into beam 313. The unrotatedlight representative of pattern 333 in beam 313 is then allowed to passthrough polarizer mirror 382 resulting in beam 317 and pattern 335.Polarized light in a second rotated state is rejected by polarizermirror 382, into beam 315 carrying the negative pixel pattern 337consisting of a light-free numeral “9”.

Other types of light valves can be substituted or used in combinationwith the described light valve. Reflective light valves, or light valvesbase on selective diffraction or refraction can also be used. In certainembodiments, non-optically addressed light valves can be used. These caninclude but are not limited to electrically addressable pixel elements,movable mirror or micro-mirror systems, piezo or micro-actuated opticalsystems, fixed or movable masks, or shields, or any other conventionalsystem able to provide high intensity light patterning. For electronbeam patterning, these valves may selectively emit electrons based on anaddress location, thus imbuing a pattern on the beam of electronsleaving the valve.

FIG. 3C is one embodiment of an additive manufacturing system thatincludes a switchyard system enabling reuse of patterned two-dimensionalenergy. Similar to the embodiment discussed with respect to FIG. 1A, anadditive manufacturing system 220 has an energy patterning system withan energy source 112 that directs one or more continuous or intermittentenergy beam(s) toward beam shaping optics 114. After shaping, the beamis two-dimensionally patterned by an energy patterning unit 230, withgenerally some energy being directed to a rejected energy handling unit222. Patterned energy is relayed by one of multiple image relays 232toward one or more article processing units 234A, 234B, 234C, or 234D,typically as a two-dimensional image focused near a movable or fixedheight bed. The bed (with optional walls) can form a chamber containingmaterial dispensed by material dispenser. Patterned energy, directed bythe image relays 232, can melt, fuse, sinter, amalgamate, change crystalstructure, influence stress patterns, or otherwise chemically orphysically modify the dispensed material to form structures with desiredproperties.

In this embodiment, the rejected energy handling unit has multiplecomponents to permit reuse of rejected patterned energy. Relays 228A,228B, and 22C can respectively transfer energy to an electricitygenerator 224, a heat/cool thermal management system 225, or an energydump 226. Optionally, relay 228C can direct patterned energy into theimage relay 232 for further processing. In other embodiments, patternedenergy can be directed by relay 228C, to relay 228B and 228A forinsertion into the energy beam(s) provided by energy source 112. Reuseof patterned images is also possible using image relay 232. Images canbe redirected, inverted, mirrored, sub-patterned, or otherwisetransformed for distribution to one or more article processing units.234A-D. Advantageously, reuse of the patterned light can improve energyefficiency of the additive manufacturing process, and in some casesimprove energy intensity directed at a bed, or reduce manufacture time.

FIG. 3D is a cartoon 235 illustrating a simple geometricaltransformation of a rejected energy beam for reuse. An input pattern 236is directed into an image relay 237 capable of providing a mirror imagepixel pattern 238. As will be appreciated, more complex pixeltransformations are possible, including geometrical transformations, orpattern remapping of individual pixels and groups of pixels. Instead ofbeing wasted in a beam dump, this remapped pattern can be directed to anarticle processing unit to improve manufacturing throughput or beamintensity.

FIG. 3E is a cartoon 235 illustrating multiple transformations of arejected energy beam for reuse. An input pattern 236 is directed into aseries of image relays 237B-E capable of providing a pixel pattern 238.

FIG. 3F and 3G illustrates a non-light based energy beam system 240 thatincludes a patterned electron beam 241 capable of producing, forexample, a “P” shaped pixel image. A high voltage electricity powersystem 243 is connected to an optically addressable patterned cathodeunit 245. In response to application of a two-dimensional patternedimage by projector 244, the cathode unit 245 is stimulated to emitelectrons wherever the patterned image is optically addressed. Focusingof the electron beam pattern is provided by an image relay system 247that includes imaging coils 246A and 246B. Final positioning of thepatterned image is provided by a deflection coil 248 that is able tomove the patterned image to a desired position on a bed of additivemanufacturing component 249.

In another embodiment supporting light recycling and reuse, multiplexmultiple beams of light from one or more light sources are provided. Themultiple beams of light may be reshaped and blended to provide a firstbeam of light. A spatial polarization pattern may be applied on thefirst beam of light to provide a second beam of light. Polarizationstates of the second beam of light may be split to reflect a third beamof light, which may be reshaped into a fourth beam of light. The fourthbeam of light may be introduced as one of the multiple beams of light toresult in a fifth beam of light. In effect, this or similar systems canreduce energy costs associated with an additive manufacturing system. Bycollecting, beam combining, homogenizing and re-introducing unwantedlight rejected by a spatial polarization valve or light valve operatingin polarization modification mode, overall transmitted light power canpotentially be unaffected by the pattern applied by a light valve. Thisadvantageously results in an effective re-distribution of the lightpassing through the light valve into the desired pattern, increasing thelight intensity proportional to the amount of area patterned.

Combining beams from multiple lasers into a single beam is one way toincreasing beam intensity. In one embodiment, multiple light beams, eachhaving a distinct light wavelength, can be combined using eitherwavelength selective mirrors or diffractive elements. In certainembodiments, reflective optical elements that are not sensitive towavelength dependent refractive effects can be used to guide amultiwavelength beam.

Patterned light can be directed using movable mirrors, prisms,diffractive optical elements, or solid state optical systems that do notrequire substantial physical movement. In one embodiment, amagnification ratio and an image distance associated with an intensityand a pixel size of an incident light on a location of a top surface ofa powder bed can be determined for an additively manufactured,three-dimensional (3D) print job. One of a plurality of lens assembliescan be configured to provide the incident light having the magnificationratio, with the lens assemblies both a first set of optical lenses and asecond sets of optical lenses, and with the second sets of opticallenses being swappable from the lens assemblies. Rotations of one ormore sets of mirrors mounted on compensating gantries and a final mirrormounted on a build platform gantry can be used to direct the incidentlight from a precursor mirror onto the location of the top surface ofthe powder bed. Translational movements of compensating gantries and thebuild platform gantry are also able to ensure that distance of theincident light from the precursor mirror to the location of the topsurface of the powder bed is substantially equivalent to the imagedistance. In effect, this enables a quick change in the optical beamdelivery size and intensity across locations of a build area fordifferent powdered materials while ensuring high availability of thesystem.

In certain embodiments, a plurality of build chambers, each having abuild platform to hold a powder bed, can be used in conjunction withmultiple optical-mechanical assemblies arranged to receive and directthe one or more incident energy beams into the build chambers. Multiplechambers allow for concurrent printing of one or more print jobs insideone or more build chambers. In other embodiments, a removable chambersidewall can simplify removal of printed objects from build chambers,allowing quick exchanges of powdered materials. The chamber can also beequipped with an adjustable process temperature controls.

In another embodiment, one or more build chambers can have a buildchamber that is maintained at a fixed height, while optics arevertically movable. A distance between final optics of a lens assemblyand a top surface of powder bed a may be managed to be essentiallyconstant by indexing final optics upwards, by a distance equivalent to athickness of a powder layer, while keeping the build platform at a fixedheight. Advantageously, as compared to a vertically moving the buildplatform, large and heavy objects can be more easily manufactured, sinceprecise micron scale movements of the build platform are not needed.Typically, build chambers intended for metal powders with a volume morethan ˜0.1-0.2 cubic meters (i.e., greater than 100-200 liters or heavierthan 500-1,000 kg) will most benefit from keeping the build platform ata fixed height.

In one embodiment, a portion of the layer of the powder bed may beselectively melted or fused to form one or more temporary walls out ofthe fused portion of the layer of the powder bed to contain anotherportion of the layer of the powder bed on the build platform. Inselected embodiments, a fluid passageway can be formed in the one ormore first walls to enable improved thermal management.

Improved powder handling can be another aspect of an improved additivemanufacturing system. A build platform supporting a powder bed can becapable of tilting, inverting, and shaking to separate the powder bedsubstantially from the build platform in a hopper. The powdered materialforming the powder bed may be collected in a hopper for reuse in laterprint jobs. The powder collecting process may be automated, andvacuuming or gas jet systems also used to aid powder dislodgement andremoval

Some embodiments of the disclosed additive manufacturing system can beconfigured to easily handle parts longer than an available chamber. Acontinuous (long) part can be sequentially advanced in a longitudinaldirection from a first zone to a second zone. In the first zone,selected granules of a granular material can be amalgamated. In thesecond zone, unamalgamated granules of the granular material can beremoved. The first portion of the continuous part can be advanced fromthe second zone to a third zone, while a last portion of the continuouspart is formed within the first zone and the first portion is maintainedin the same position in the lateral and transverse directions that thefirst portion occupied within the first zone and the second zone. Ineffect, additive manufacture and clean-up (e.g., separation and/orreclamation of unused or unamalgamated granular material) may beperformed in parallel (i.e., at the same time) at different locations orzones on a part conveyor, with no need to stop for removal of granularmaterial and/or parts.

In another embodiment, additive manufacturing capability can be improvedby use of an enclosure restricting an exchange of gaseous matter betweenan interior of the enclosure and an exterior of the enclosure. Anairlock provides an interface between the interior and the exterior;with the interior having multiple additive manufacturing chambers,including those supporting power bed fusion. A gas management systemmaintains gaseous oxygen within the interior at or below a limitingoxygen concentration, increasing flexibility in types of powder andprocessing that can be used in the system.

In another manufacturing embodiment, capability can be improved byhaving a 3D printer contained within an enclosure, the printer able tocreate a part having a weight greater than or equal to 2,000 kilograms.A gas management system may maintain gaseous oxygen within the enclosureat concentrations below the atmospheric level. In some embodiments, awheeled vehicle may transport the part from inside the enclosure,through an airlock, since the airlock operates to buffer between agaseous environment within the enclosure and a gaseous environmentoutside the enclosure, and to a location exterior to both the enclosureand the airlock.

Other manufacturing embodiments involve collecting powder samples inreal-time in a powder bed fusion additive manufacturing system. Aningester system is used for in-process collection and characterizationsof powder samples. The collection may be performed periodically and theresults of characterizations result in adjustments to the powder bedfusion process. The ingester system can optionally be used for one ormore of audit, process adjustments or actions such as modifying printerparameters or verifying proper use of licensed powder materials.

Yet another improvement to an additive manufacturing process can beprovided by use of a manipulator device such as a crane, lifting gantry,robot arm, or similar that allows for the manipulation of parts thatwould be difficult or impossible for a human to move is described. Themanipulator device can grasp various permanent or temporary additivelymanufactured manipulation points on a part to enable repositioning ormaneuvering of the part.

FIG. 4 is an example apparatus of dynamic optical assembly 400 capableof configuring a magnification ratio on the fly for different powderedmaterials without shutting down the additive manufacturing system andre-installing the optics assembly. Dynamic optical assembly 400 mayperform various functions related to techniques, methods and systemsdescribed herein, including those described below with respect toprocess 1700. Dynamic optical assembly 400 may be installed in, equippedon, connected to or otherwise implemented in a laser-based powder bedfusion additive manufacturing system as described above with respect toFIGS. 1A-3B to effect various embodiments in accordance with the presentdisclosure. Dynamic optical assembly 400 may include at least some ofthe components illustrated in FIG. 4.

Dynamic optical assembly 400 may include a mechanical assembly 450 whichmay include a set of lens assemblies 440(1)-440(K), with K being apositive integer. Each of the lens assemblies 440(1)-440(K) may beassociated with a respective magnification ratio which magnifies a firstimage in a specified precursor image plane 492 located before the firstlens of lens assemblies 440(1)-440(K) to a second image of the same ordifferent size on the print surface-final image plane 494. Mechanicalassembly 450 may be operable to select, switch, or position one of thelens assemblies 440(1)-440(K) to receive an incident light beam providedby an energy source 410 (e.g., solid state or semiconductor laser). Theoperation of mechanical assembly 450 described above may result in nointerruptions of additive manufacturing when changing the powderedmaterials and, therefore, ensue high availability of the additivemanufacturing system.

The lens assemblies 440(1)-440(K) may include a plurality of first setsof optical lenses 420(1)-420(K) and a plurality of second sets opticallens 430(1)-430(K), respectively. That is, each lens assembly 440(Y) oflens assemblies 440(1)-440(K) may respectfully include a respectivefirst set of optical lenses 420(Y) and a respective second set ofoptical lenses 430(Y), where Y is between 1 and K. Second sets ofoptical lenses 430(1)-430(K) may be detachable from the lens assemblies440(1)-440(K) to allow a swap or a removal of second sets of opticallenses 430(1)-430(K) from the lens assemblies 440(1)-440(K). A swap or aremoval of second sets of optical lenses 430(1)-430(K) may allow furthertuning in configuring a magnification ratio for a powdered materialsince each powdered material may have a different threshold of bondingenergy. Swapping or removing of second sets of optical lenses430(1)-430(K) may be performed manually or, alternatively, automaticallyby operations of mechanical assembly 450.

In some embodiments, dynamic optical assembly 400 may further include aprecursor mirror 460 and a build platform gantry 470 with a finalmirrors 480 mounted on build platform gantry 470. Build platform gantry470 may be mounted at a vertical distance above a powder bed. Precursormirror 460 may be capable of rotations and may direct an incident lightreceived from one of the lens assemblies 440(1)-440(K) to final mirror480. Final mirror 480 on build platform gantry 470 may be capable oftranslational movements in two degrees of freedom and rotations in onedegree of freedom to receive the incident light from precursor mirror460 and direct the incident light toward the powder bed, e.g., the buildarea of a printed object.

FIG. 5 illustrates a lens assembly 503 for laser-based powder bed fusionadditive manufacturing showing 4× de-magnification. Lens assembly 503may be an implementation of lens assembly 440(1)-440(K) in apparatus400. In the example shown in FIG. 5, a beam of 1000 nm laser light 502,5 cm wide and 5 cm tall, contains image information in plane 501. Lensassembly 503, which includes a convex lens 504, a convex lens 506, and aconvex lens 508 aligned along an optical axis of lens assembly 503,causes a 4× de-magnification in the laser beam and re-creates the imageof plane 501 on plane 510. Beam 502 passes through convex lens 504 toform beam 505 which passes through convex lens 506 to form beam 507which passes through convex lens 508 to form beam 509 which is incidenton a top surface of a powder bed at plane 510 in a 2.5 cm wide by 2.5 cmtall square.

FIG. 6 illustrates a lens assembly 611 for laser-based powder bed fusionadditive manufacturing showing 25× de-magnification. Lens assembly 611may be an implementation of lens assembly 440(1)-440(K) in apparatus400. In the example shown in FIG. 6, a beam of 1000 nm laser light 602,5 cm wide and 5 cm tall, contains image information in plane 601. Lensassembly 611, which includes a convex lens 612, a convex lens 614, and aconvex lens 616 aligned along an optical axis of lens assembly 611,causes a 4× de-magnification in the laser beam and re-creates the imageof plane 601 on plane 618. Beam 602 passes through convex lens 612 toform beam 613 which passes through convex lens 614 to form beam 615which passes through convex lens 616 to form beam 617 which is incidenton a top surface of the powder bed at plane 618 in a 1 cm wide and 1 cmtall square.

FIG. 7 illustrates a system 700 having a lens assembly 719 forlaser-based powder bed fusion additive manufacturing showing 4×magnification. Lens assembly 719 may be an implementation of lensassembly 440(1)-440(K) in apparatus 400. In the example shown in FIG. 7,a beam of 1000 nm laser light 702, 5 cm wide and 5 cm tall, containsimage information in plane 701. Lens assembly 719, which includes aconcave lens 720, a concave lens 722, and a concave lens 724 alignedalong an optical axis of lens assembly 719, causes a 4× magnification inthe laser beam and re-creates the image of plane 701 on plane 726. Beam702 passes through concave lens 720 to form beam 721 which passesthrough concave lens 722 to form beam 723 which passes through concavelens 724 to form beam 725 which is incident on a top surface of thepowder bed at plane 726 in a 10 cm by 10 cm square.

FIG. 8 illustrates a lens assembly swapping mechanism 803 for changingout optics by rotating new ones into place. This mechanism 803 usesrotations to swap out various lens assemblies 503, 611, and 719 whichare installed in barrel 801. The rotations of barrel 801 may beperformed with respect to the longitudinal axis of barrel 801, which isalso parallel to the optical axes of the lens assemblies 503, 611, and719. Lens assembly 503 contains convex lens 504, convex lens 506, andconvex lens 508 as shown in FIG. 5; lens assembly 611 contains convexlens 612, convex lens 614, and convex lens 616 as shown in FIG. 6; andlens assembly 719 contains concave lens 720, concave lens 722, andconcave lens 724 as shown in FIG. 7. In certain embodiments, the lensassembly swapping mechanism may not require physical replacement oflenses in the lens assemblies. Instead, the image size and/or shape maybe dynamically modulated by exerting electromagnetic or mechanicaleffects on special lenses of which the reflective/refractive propertiesmay respond to such effects and cause a change of the magnificationratio. That is, in some embodiments in accordance with the presentdisclosure, “swapping out” of the optics may be achieved not byphysically replacing the optics, but by dynamically changing the optics.For example, a lens capable of modulating its shape under the control ofelectric, magnetic and/or optic drive effect may be utilized.

In some embodiments, linear translational movements of lenses 504, 506,and 508 inside lens assembly 503 (or lenses 612, 614, and 616 insidelens assembly 611, or lenses 720, 722, and 724 inside lens assembly 719)may be used to change the magnification ratios for the respective lensassembly. When the distance between a pair of lenses among lenses 504,506, and 508 changes, the magnification ratio of lens assembly 503 maychange accordingly.

FIG. 9 illustrates a swap of two sets of optical lenses for laser-basedpowder bed fusion additive manufacturing showing 4× de-magnificationchanging to 25× de-magnification when a first set of optical lenses 927and a second set of optical lenses 928 are swapped. Another set ofoptical lenses including convex lens 904 may be non-detachable ornon-swappable. In the example shown in FIG. 9, a beam of 1000 nm laserlight 902, in a 5 cm wide and 5 cm tall beam, contains image informationin plane 901. A swappable lens assembly 927, which includes a convexlens 906 and a convex lens 908, causes a 4× de-magnification in thelaser beam and re-creates the image of plane 901 on plane 910. Beam 902passes through convex lens 904 to form beam 905 which passes throughconvex lens 906 to form beam 907 which passes through convex lens 908 toform beam 909 which is incident on the top surface of the powder bed atplane 910 in a 2.5 cm wide and 2.5 cm tall square. The first set ofoptical lenses 927 is swappable with the second set of optical lenses928 to allow for different projected intensities on a top surface of thepowder bed. When swapped, a convex lens 929 and a convex lens 931 areswapped in to take place of convex lens 906 and convex lens 908, thusconverting beam 907 and beam 909 to beam 930 and beam 932 at a new imageplane 933, thereby converting the image into a 1 cm wide and 1 cm tallsquare at plane 933.

FIG. 10 illustrates a swap of two sets of optical lenses for laser-basedpowder bed fusion additive manufacturing showing 4× de-magnificationchanging to 2× magnification when a first set of optical lenses 1039 anda second set of optical lenses 1034 are swapped. Another set of opticallenses including convex lens 1104 and convex lens 1108 may benon-detachable or non-swappable. In the example shown in FIG. 10, a beamof 1000 nm laser light 1002, in a 5 cm wide and 5 cm tall beam, containsimage information in plane 1001. A swappable first set of optical lenses1039, which includes convex lens 1006, causes a 4× de-magnification inthe laser beam and re-creates the image of plane 1001 on plane 1010.Beam 1002 passes through convex lens 1004 to form beam 1005 which passesthrough convex lens 1006 to form beam 1007 which passes through convexlens 1008 to form beam 1009 which is incident on a top surface of thepowder bed at plane 1010 in a 2.5 cm wide and 2.5 cm tall square. Thesecond set of optical lenses 1034 is swappable with the first set ofoptical lenses 1039 to allow for different projected intensities on thetop surface of the powder bed. When swapped, concave lens 1035 isswapped in to take place of convex lens 1006, thus converting beam 1007and beam 1009 to beam 1036 and beam 1037 at a new image plane 1038,thereby resulting in a converted image at plane 1038 of a 10 cm wide and10 cm tall square.

FIG. 11 illustrates a removal of second sets of optical lenses forlaser-based powder bed fusion additive manufacturing showing 4×de-magnification changing to 2× magnification when a first set ofoptical lenses 1139 is removed. Another set of optical lenses includingconvex lens 1104 and convex lens 1108 may be non-detachable ornon-swappable. In the example shown in FIG. 11, a beam of 1000 nm laserlight 1102, in a 5 cm wide and 5 cm tall beam, contains imageinformation in plane 1101. A swappable first set of optical lenses 1139,which includes a convex lens 1106, causes a 4× de-magnification in thelaser beam and re-creates the image of plane 1101 on plane 1110. Beam1102 passes through lens 1104 to form beam 1105 which passes throughconvex lens 1106 to form beam 1107 which passes through convex lens 1108to form beam 1109 which is incident on the powder bed at plane 1110 in a2.5 cm wide and 2.5 cm tall square. The first set of optical lenses 1139is swappable with a second set of optical lenses 1140 to allow fordifferent projected intensities on a top surface of the powder bed. Inthe example shown in FIG. 11, the second set of optical lenses 1140contains no lens. When swapped, convex lens 1106 is removed, thusconverting beam 1105 and beam 1107 to beam 1141, and beam 1109 to beam1143 at a new image plane 1144, thereby resulting in a converted imageat plane 1144 of a 10 cm wide and 10 cm tall square.

As powder bed fusion additive manufacturing systems grow in speed andsize for larger objects, the optical system in laser-based powder bedfusion additive manufacturing systems need to be adjusted to handleresolution requirements. When operating on a light source that is highlydivergent and un-collimated, such as with laser lasers, care must beused to ensure that high resolution imaging is maintained. The dynamicoptical assembly of the present disclosure is capable of high-resolutionimage relay operations over large distances and large print surface. Apart of the dynamic optical assembly may focus on the translationalposition control of the optics over the powder bed to maintainhigh-resolution imaging while directing the laser beam to all possiblelocations on the powder bed.

The distances between lenses are designed for a specific focal lengthover a focal plane in an optical system. If the print surface (where animage of the object is formed) coincides with the focal plane of thefinal optics in the optical system, then a good resolution of theprinted object may be obtained. The focal plane may not be a flat planebut with a curvature, and in cases of forming a large object inlaser-based powder bed fusion additive manufacturing, some locations onthe top surface of the powder bed may lie outside of the focal plane. Insome embodiments, a dynamic optical assembly in accordance with thepresent disclosure may control an imaging distance (or a focal length,or a depth of field) between a source imaging plane and locations on thetop surface of the powder bed by adjusting the distance between lens tocompensate for the change of the imaging distance due to differentlocations. The control of the imaging distance may be realized bytranslational movements and rotations of mirrors and lens mounted on aset of gantries capable of moving along a plane parallel to the topsurface of the powder bed (print surface).

FIG. 12 illustrates an example apparatus of dynamic optical assembly1200 capable of controlling an image distance for high resolutionimaging on locations over an entire print surface accordance with anembodiment of the present disclosure. Dynamic optical assembly 1200 mayperform various functions related to techniques, methods and systemsdescribed herein, including those described below with respect toprocess 1700. Dynamic optical assembly 1200 may be installed in,equipped on, connected to or otherwise implemented in a laser-basedpowder bed fusion additive manufacturing system as described above withrespect to FIGS. 1A-3B to effect various embodiments in accordance withthe present disclosure. Dynamic optical assembly 1200 may include atleast some of the components illustrated in FIG. 12.

In some embodiments, dynamic optical assembly 1200 may include aprecursor mirror 1240, at least one compensating gantry, build platformgantry 1290. For illustrative purpose and without limitation, the atleast one compensating gantry is shown in FIG. 12 as a set ofcompensating gantries 1260(1)-1260(X), with X being a positive integergreater than 0. The compensating gantries 1260(1)-1260(X) may includesets of mirrors 1250(1)-1250(N), 1251(1)-1251(N), . . . ,125X(1)-125X(N), with N a positive integer. Each set of the mirrors1250(1)-1250(N), 1251(1)-1251(N), . . . , 125X(1)-125X(N) may be mountedon the respective compensating gantries 1260(1)-1260(X). In someembodiments, at least one set of mirrors 1250(1)-1250(N) may be mountedon the one of the compensating gantries 1260(1)-1260(X). Build platformgantry 1290 may include a final set of mirrors 1270(1)-1270(J), with J apositive integer. In some embodiments, build platform gantry 1290 mayfurther include final lens 1280. Build platform gantry 1290 may bemounted at a vertical distance above the print surface and thecompensating gantries 1260(1)-1260(X) may be mounted at a horizontaldistance next to build platform gantry 1290. Precursor mirror 1240 mayreflect off an incident light containing an image at a precursor imageplane towards compensating gantries. Sets of mirrors 1250(1)-1250(N),1251(1)-1251(N), . . . , 125X(1)-125X(N) on the compensation gantries1260(1)-1260(X) may be capable of translational movements and rotationsso as to direct the incident light received from precursor mirror 1240towards build platform gantry 1290. Final set of mirrors 1270(1)-1270(J)on build platform gantry 1290 may be capable of translational movementsand rotations so as to direct the incident light received fromcompensating gantries 1260(1)-1260(X) towards the print surface. Thetranslational movements of sets of mirrors 1250(1)-1250(N),1251(1)-1251(N), . . . , 125X(1)-125X(N) on compensating gantries1260(1)-1260(X) and final set of mirrors 1270(1)-1270(J) on buildplatform gantry 1290 may serve to control a constant image distancebetween lenses for maintaining an image resolution during the imagerelay from the precursor image plane and the print surface. Therotations of sets of mirrors 1250(1)-1250(N), 1251(1)-1251(N), . . . ,125X(1)-125X(N) on compensating gantries 1260(1)-1260(X) and final setof mirrors 1270(1)-1270(J) on build platform gantry 1290 may serve todirect the incident light to various locations on the print surface.

In some embodiments, dynamic optical assembly 1200 may include onecompensating gantry 1260(1) mounted with one mirror 1250(1). Dynamicoptical assembly 1200 may further include precursor mirror 1240 andbuild platform gantry 1290 mounted with one final mirror 1270(1) andfinal lens 1280. Precursor mirror 1240, directing the incident lightfrom the precursor image plane, may be incapable of rotations andtranslational movements. Precursor mirror 1240, directing the incidentlight from the precursor image plane, may direct an incident lighttowards mirror 1250(1) on compensating gantry 1260(1). Mirror 1250(1)may be capable of a rotation in one degree of freedom and atranslational movement in one degree of freedom. Mirror 1250(1) mayfurther direct light towards final mirror 1270(1) on build platformgantry 1290. Final mirror 1270(1) may be capable of rotations in twodegrees of freedom and translational movements in two degree of freedomso as to direct the incident light passing through final lens 1280 toall locations on the print surface. Final lens 1280 may be fixed belowrelative to final mirror 1270(1) and moves synchronously with finalmirror 1270(1).

In some embodiments, dynamic optical assembly 1200 may further include aprocessor 1201 and a memory 1202 to facilitate controlling of positionsand rotations of sets of mirrors 1250(1)-1250(N), 1251(1)-1251(N), . . ., 125X(1)-125X(N) on compensating gantries 1260(1)-1260(X) and finalmirror 1270 on build platform gantry 1290. Memory 1202 storinginstructions or programs for configuring relative positons and angles ofsets of mirrors 1250(1)-1250(N), 1251(1)-1251(N), . . . ,125X(1)-125X(N) and final set of mirrors 1270(1)-1270(J) to maintain aconstant image distance across the entire print surface.

In some embodiments, dynamic optical assembly 1200 may further include aplurality of lens assemblies 440(1)-440(K) and a mechanical assembly 450of apparatus 400 to be able to change magnification ratios on-the-flyfor different powdered materials. Lens assemblies 440(1)-440(K) mayinclude first sets of optical lenses 420(1)-420(K) and second sets ofoptical lenses 430(1)-430(K) respectively as in apparatus 400.

FIG. 13 illustrates an example scenario 1300 as in embodiments describedabove in accordance with the present disclosure. Scenario 1300illustrates a near-point print as to how compensating gantry and buildplatform gantry may compensate for a change of the imaging location. InFIG. 13, build platform gantry is made of rail 5, rail 6, and rail 66.Final mirror 2 is mounted on podium 3 and supports fixed final lens 1.Final mirror 2 is capable of rotations in two degrees of freedom. Buildplatform gantry (rail 5, rail 6, and rail 66) is mounted above a powderbed 4, and is capable of a translational motion in the x-direction 9 onrail 5 and in the y-direction 10 on rail 6. Y-directional rail 6 andrail 66 are mounted on wall 7 and wall 77 respectively, which sandwich abuild platform 8 therebetween. Build platform 8 is capable of a verticaltranslational motion up and down. A patterned beam of light 11, whichincludes a 4 cm×4 cm beam of 1000 nm light containing 18.75 kW of power,may be emanated from an energy source (e.g., semiconductor laser), maycontain image information in a precursor image plane 30, and may thenreflect off of precursor mirror 12 mounted on post 13 which is incapableof movements and rotations. The beam of light 14 leaving the precursormirror 12 reflects a second time off of mirror 15 which is mounted topodium 16 on compensating gantry platform of rail 17, and capable ofrotation in one axis, and horizontal translation in the x-direction 9 onrail 17. The beam of light 18 leaving mirror 15 reflects off of finalmirror 2 passes through final lens 1 which focuses the light in beam 19to a 1 cm×1 cm square achieving intensities of 300 kW/cm² at the topsurface of powder bed 4 (print surface) to melt a pattern in a printedimage 20. The current position of podium 16 is such that the distancethe light travels is constant and that the distance 22 of 40 cm betweenprecursor mirror 12 and mirror 15 plus the distance 23 of 60 cm betweenmirror 15 and final mirror 2 is at a constant value (100 cm) for every xand y position of podium 3 and corresponding x-position of podium 16. Itis noteworthy that the dimensions and values referenced herein are forillustrative purposes and without limitation. That is, the scope of thepresent disclosure is limited to the specific example shown anddescribed in FIG. 13.

FIG. 14 illustrates an example scenario 1400 as in embodiments describedabove in accordance with the present disclosure. Scenario 1400illustrates a fart-point print as to how compensating gantry and buildplatform gantry may compensate for a change of the imaging location. InFIG. 14, build platform gantry is made of rail 5, rail 6, and rail 66.Final mirror 2 is mounted on podium 3 also supporting fixed final lens1. Final mirror 2 is capable of rotations in two degrees of freedom.Build platform gantry (rail 5, rail 6, and rail 66) is mounted above apowder bed 4, and is capable of translational motion in the x-direction9 on rail 5 and in the y-direction 10 on rail 6. Y-directional rail 6and rail 66 are mounted on wall 7 and wall 77 respectively, whichsandwich the main build platform 8 therebetween. Build platform 8 iscapable of relative translational motion up and down. A patterned beamof light 11, which includes a 4 cm×4 cm beam of 1000 nm light containing18.75 kW of power, may emanate from the additive manufacturing opticalsystem, may contain image information in a precursor image plane 30, andmay reflect off of precursor mirror 12 mounted on post 13 which isincapable of movements and rotations. The beam of light 14 leavingprecursor mirror 12 reflects a second time off of mirror 15 which ismounted to podium 16, and capable of rotation in one axis, andhorizontal translation in the x-direction 9 on compensating gantry ofrail 17. The beam of light 18 leaving mirror 15 reflects off of finalmirror 2 passes through final lens 1 which focuses the light in beam 19to a 1 cm×1 cm square achieving intensities of 300 kW/cm² at the topsurface of powder bed 4 (print surface) to melt a pattern in a printedimage 20. The current position of the podium 16 is such that thedistance the light travels is constant and that the distance 22 of 20 cmbetween precursor mirror 12 and mirror 15 plus the distance 23 of 80 cmbetween mirror 15 and final mirror 2 is at a constant value (100 cm) forevery x and y position of podium 3 and corresponding x-position ofpodium 16. It is noteworthy that the dimensions and values referencedherein are for illustrative purposes and without limitation. That is,the scope of the present disclosure is limited to the specific exampleshown and described in FIG. 14.

FIG. 15 illustrates an example scenario 1500 as in embodiments describedabove in accordance with the present disclosure. Scenario 1500illustrates a near-point print as to how compensating gantry and buildplatform gantry may compensate for a change of the imaging location. InFIG. 15, build platform gantry is made of rail 5, rail 6, and rail 66.Final mirror 2 is mounted on podium 3 also supporting fixed final lens1. Final mirror 2 is capable of a rotation in one degree of freedom.Build platform gantry (rail 5, rail 6, and rail 66) is mounted above apowder bed 4, and is capable of translational motion in the x-direction9 on rail 5 and in the y-direction 10 on rail 6. Y-directional rail 6and rail 66 are mounted on wall 7 and wall 77, which sandwich the mainbuild platform 8 therebetween. Build platform 8 is capable of relativetranslational motion up and down. A patterned beam of light 11, whichincludes a 4 cm×4 cm beam of 1000 nm light containing 18.75 kW of power,may emanate from the additive manufacturing optical system, may containimage information in a precursor image plane 30, and may reflect off ofprecursor mirror 12 mounted on post 13 which is capable of rotation inone degree of freedom. The beam of light 14 leaving precursor mirror 12reflects a second time off of mirror 15 which is mounted to podium 16,and capable of rotation in one axis, horizontal translation in thex-direction 9 on compensating gantry of rail 17, as well as translationin the y-direction 10 on rail 21. The beam of light 18 leaving mirror 15reflects off of final mirror 2 passes through final lens 1 which focusesthe light in beam 19 to a 1 cm×1 cm square achieving intensities of 300kW/cm² at the top surface of powder bed 4 (print surface) to melt apattern in a printed image 20. The current position of the podium 16 issuch that the distance the light travels is constant and that the squareroot of the square of the distance 24 in the x-direction 9 of 10 cmbetween precursor mirror 12 and mirror 15 plus the square of distance 25in the y-direction 10 of 10 cm (√{square root over (10²+10²)}=14.14 cm)plus the distance 23 of 85.86 cm between mirror 15 and mirror 2 is at aconstant value (100 cm) for every x and y position of podium 3 andcorresponding x and y positions of podium 16. It is noteworthy that thedimensions and values referenced herein are for illustrative purposesand without limitation. That is, the scope of the present disclosure islimited to the specific example shown and described in FIG. 15.

FIG. 16 illustrates an example scenario 1600 as in embodiments describedabove in accordance with the present disclosure. Scenario 1600illustrates a far-point print as to how compensating gantry and buildplatform gantry may compensate for a change of the imaging location. InFIG. 16, build platform gantry is made of rail 5, rail 6, and rail 66.Final mirror 2 is capable of a rotation in one degree of freedom. Buildplatform gantry (rail 5, rail 6, and rail 66) is mounted above a powderbed 4, and is capable of translational motion in the x-direction 9 onrail 5 and in the y-direction 10 on rail 6. Y-directional rail 6 andrail 66 are mounted on wall 7 and wall 77, which sandwich the main buildplatform 8 therebetween. Build platform 8 is capable of relativetranslational motion up and down. A patterned beam of light 11, whichincludes a 4 cm×4 cm beam of 1000 nm light containing 18.75 kW of power,may emanate from the additive manufacturing optical system, may containimage information in a precursor image plane 30, and may reflect off ofprecursor mirror 12 mounted on post 13 which is capable of rotation inone degree of freedom. The beam of light 14 leaving precursor mirror 12reflects a second time off of mirror 15 which is mounted to podium 16,and capable of rotation in one axis, horizontal translation in thex-direction 9 on compensating gantry of rail 17, as well as translationin the y-direction 10 on rail 21. The beam of light 18 leaving mirror 15reflects off of final mirror 2 passes through final lens 1 which focusesthe light in beam 19 to a 1 cm×1 cm square achieving intensities of 300kW/cm² at the top surface of powder bed 4 (print surface) to melt apattern in a printed image 20. The current position of podium 16 is suchthat the distance the light has to travel is constant and that thesquare root of the square of the distance 24 in the x-direction 9 of 45cm between precursor mirror 12 and mirror 15 plus the square of distance25 in the y-direction 10 of 10 cm (√{square root over (10²+45²)}=46.1cm) plus the distance 23 of 53.9 cm between mirror 15 and final mirror 2is at a constant value (100 cm) for every x and y position of podium 3and corresponding x and y positions of podium 16. It is noteworthy thatthe dimensions and values referenced herein are for illustrativepurposes and without limitation. That is, the scope of the presentdisclosure is limited to the specific example shown and described inFIG. 16.

FIG. 17 illustrates an example process 1700 in accordance with thepresent disclosure. Process 1700 may be utilized to print an object in alaser-based powder bed fusion additive manufacturing system inaccordance with the present disclosure. Process 1700 may include one ormore operations, actions, or functions shown as blocks such as 1710,1720, 1730, and 1740. Although illustrated as discrete blocks, variousblocks of process 1700 may be divided into additional blocks, combinedinto fewer blocks, or eliminated, depending on the desiredimplementation, and may be performed or otherwise carried out in anorder different from that shown in FIG. 17. Process 1700 may beimplemented by a combination of dynamic optical assembly 400 and dynamicoptical assembly 1200. For illustrative purposes and without limitingthe scope of process 1700, the following description of process 1700 isprovided in the context of dynamic optical assembly 1200. Process 1700may begin with block 1710.

At 1710, process 1700 may involve processor 1201 of dynamic opticalassembly 1200 obtaining or otherwise determining information ofintensity of light (or energy) required for a powdered material to bebonded in a powder bed fusion additive manufacturing system as describedin FIGS. 1A-3B. Process 1700 may further involve processor 1201obtaining or otherwise determining a minimum resolution (a pixel size ofan incident light) for an object to be printed in the powder bed fusionadditive manufacturing system. According to the intensity and resolutionrequirements, process 1700 may involve processor 1201 determining amagnification ratio of the incident light containing an imageinformation and an image distance of dynamic optical assembly 1200associated with the intensity and resolution requirements respectively.The magnification ratio may transfer a first size of the image at aprecursor image plane to a second size of the image at the print surface(top surface of a powder bed). The incident light may be originated fromenergy source 1210 and passes through the precursor image plane at whichthe image information may be created. Process 1700 may involve memory1202 of dynamic optical assembly 1200 storing geometrical data of theobject, positional and rotational control data of precursor mirror 1240,sets of mirrors 1250(1)-1250(N), 1251(1)-1251(N), . . . ,125X(1)-125X(N), and final set of mirrors 1270(1)-1270(J) in eachsuccessive step of powder bed fusion additive manufacturing. Process1700 may proceed from 1710 to 1720.

At 1720, process 1700 may involve processor 1201 configuring mechanicalassembly 450 and one or more of lens assemblies 440(1)-440(K) of dynamicoptical assembly 1200 to achieve the magnification ratio obtained at1710 suitable for the powdered material. The configuring of mechanicalassembly 450 and one of lens assemblies 440(1)-440(K) may involve arotation of mechanical assembly 450, a swap of second sets of opticallenses 430(1)-430(K), or a removal of a second set of optical lenses430(1)-430(K). Process 1700 may proceed from 1720 to 1730.

At 1730, process 1700 may involve processor 1201 controlling precursormirror 1240, sets of mirrors 1250(1)-1250(N), 1251(1)-1251(N), . . . ,125X(1)-125X(N), final set of mirrors 1270(1)-1270(J) of dynamic opticalassembly 1200 to perform a plurality of rotations to direct the incidentlight from the precursor image plane to the print surface at a desiredlocation on the print surface (e.g., top surface of a powder bed) ineach successive step of powder bed fusion additive manufacturing.Process 1700 may proceed from 1730 to 1740.

At 1740, process 1700 may involve processor 1201 controlling sets ofmirrors 1250(1)-1250(N), 1251(1)-1251(N), . . . , 125X(1)-125X(N), finalset of mirrors 1270(1)-1270(J) of dynamic optical assembly 1200 toperform a plurality of translational movements to maintain a constantimage distance from the precursor image plane to every location of theprint surface (e.g., top surface of a powder bed) in each successivestep of powder bed fusion additive manufacturing. At 1730 and 1740,processor 1201 may control the vertical motion of the powder bed tomaintain a fixed separation with final lens 1280.

Moreover, process 1700 may involve processor 1201 performing steps 1730and 1740 in parallel or in reverse order. Alternatively, process 1700may involve processor 1201 performing either step 1730 or step 1740only, or none of steps 1730 and 1740.

FIG. 18 illustrates an example implementation of dynamic opticalassembly 1200 according to process 1700 in accordance with the presentdisclosure. A layer of a powdered material is dispensed on a top surfaceof a powder bed 1830 supported by a build platform 1840. Source image1801 of an incident light located at a precursor image plane is incidentupon lens assembly 503 in barrel 801. Lens assembly 503 may beconfigured by a rotation 803 of barrel 801 that effect a swap of asecond set of optical lenses (e.g. lenses 603), a removal of a secondset of optical lenses, use of dynamic lenses that change shape,electronic lens swapping, beam redirect systems, electro-opticallycontrolled refractive beam steering devices, or a combination thereof,to have a suitable magnification ratio for the powdered material. Thebeam containing image information of 1801 is incident on precursormirror 1860 and is directed to mirror 1850 mounted on compensatinggantry 1880 where it reflects off mirror 1850 and then is incident onfinal mirror 1810 mounted on build platform gantry 1820. Final mirror1810 directs the beam containing image information 1801 through a finallens 1870 toward a top surface of a powder bed 1830 and object image1801 is recreated and magnified in image plane 1805 which may be formedthereon. Alternatively, a transmissive beam steering device can be usedin place of 1810 to direct the beam around the build platform. Objectimage 1805 may be of a size different than source image 1801 afterpassing through lens assembly 503 and traversing the optical path fromprecursor mirror 1860 to the top surface of powder bed 1830 and may bemodified according to the magnification ratios of lens assembly 503and/or final lens 1870. The powdered material on powder bed 1830 maymelt to form a shape of object image 1805. Build platform gantry 1820then moves to a next location until designated locations on the topsurface of powder bed 1830 are bonded for that layer. A new layer of thepowdered material is dispensed again and the build platform 1840 maymove down a distance equal to the thickness of the layer of the powderedmaterial to keep a constant distance to the build platform gantry 1820.The cycle starts for the new layer in continuing the additive printingprocess.

In the above disclosure, reference has been made to the accompanyingdrawings, which form a part hereof, and in which is shown by way ofillustration specific implementations in which the present disclosuremay be practiced. It is understood that other implementations may beutilized and structural changes may be made without departing from thescope of the present disclosure. References in the specification to “oneembodiment,” “an embodiment,” “an example embodiment,” etc., indicatethat the embodiment described may include a particular feature,structure, or characteristic, but every embodiment may not necessarilyinclude the particular feature, structure, or characteristic. Moreover,such phrases are not necessarily referring to the same embodiment.Further, when a particular feature, structure, or characteristic isdescribed in connection with an embodiment, it is submitted that it iswithin the knowledge of one skilled in the art to affect such feature,structure, or characteristic in connection with other embodimentswhether or not explicitly described.

Implementations of the systems, apparatuses, devices, and methodsdisclosed herein may comprise or utilize a special purpose orgeneral-purpose computer including computer hardware, such as, forexample, one or more processors and system memory, as discussed herein.Implementations within the scope of the present disclosure may alsoinclude physical and other computer-readable media for carrying orstoring computer-executable instructions and/or data structures. Suchcomputer-readable media may be any available media that may be accessedby a general purpose or special purpose computer system.Computer-readable media that store computer-executable instructions arecomputer storage media (devices). Computer-readable media that carrycomputer-executable instructions are transmission media. Thus, by way ofexample, and not limitation, implementations of the present disclosuremay comprise at least two distinctly different kinds ofcomputer-readable media: computer storage media (devices) andtransmission media.

Computer storage media (devices) includes RAM, ROM, EEPROM, CD-ROM,solid state drives (“SSDs”) (e.g., based on RAM), Flash memory,phase-change memory (“PCM”), other types of memory, other optical diskstorage, magnetic disk storage or other magnetic storage devices, or anyother medium which may be used to store desired program code means inthe form of computer-executable instructions or data structures andwhich may be accessed by a general purpose or special purpose computer.

An implementation of the devices, systems, and methods disclosed hereinmay communicate over a computer network. A “network” is defined as oneor more data links that enable the transport of electronic data betweencomputer systems and/or modules and/or other electronic devices. Wheninformation is transferred or provided over a network or anothercommunications connection (either hardwired, wireless, or anycombination of hardwired or wireless) to a computer, the computerproperly views the connection as a transmission medium. Transmissionsmedia may include a network and/or data links, which may be used tocarry desired program code means in the form of computer-executableinstructions or data structures and which may be accessed by a generalpurpose or special purpose computer. Combinations of the above shouldalso be included within the scope of computer-readable media.

Computer-executable instructions comprise, for example, instructions anddata which, when executed at a processor, cause a general purposecomputer, special purpose computer, or special purpose processing deviceto perform a certain function or group of functions. The computerexecutable instructions may be, for example, binaries, intermediateformat instructions such as assembly language, or even source code.Although the subject matter has been described in language specific tostructural features and/or methodological acts, it is to be understoodthat the subject matter defined in the appended claims is notnecessarily limited to the described features or acts described above.Rather, the described features and acts are disclosed as example formsof implementing the claims.

Further, where appropriate, functions described herein may be performedin one or more of: hardware, software, firmware, digital components, oranalog components. For example, one or more application specificintegrated circuits (ASICs) may be programmed to carry out one or moreof the systems and procedures described herein. Certain terms are usedthroughout the description and claims to refer to particular systemcomponents. As one skilled in the art will appreciate, components may bereferred to by different names. This document does not intend todistinguish between components that differ in name, but not function.

It should be noted that the sensor embodiments discussed above maycomprise computer hardware, software, firmware, or any combinationthereof to perform at least a portion of their functions. For example, asensor may include computer code configured to be executed in one ormore processors, and may include hardware logic/electrical circuitrycontrolled by the computer code. These example devices are providedherein purposes of illustration, and are not intended to be limiting.Embodiments of the present disclosure may be implemented in furthertypes of devices, as would be known to persons skilled in the relevantart(s).

At least some embodiments of the present disclosure have been directedto computer program products comprising such logic (e.g., in the form ofsoftware) stored on any computer useable medium. Such software, whenexecuted in one or more data processing devices, causes a device tooperate as described herein.

While various embodiments of the present disclosure have been describedabove, it should be understood that they have been presented by way ofexample only, and not limitation. It will be apparent to persons skilledin the relevant art that various changes in form and detail may be madetherein without departing from the spirit and scope of the presentdisclosure. Thus, the breadth and scope of the present disclosure shouldnot be limited by any of the above-described exemplary embodiments, butshould be defined only in accordance with the following claims and theirequivalents. The foregoing description has been presented for thepurposes of illustration and description. It is not intended to beexhaustive or to limit the present disclosure to the precise formdisclosed. Many modifications and variations are possible in light ofthe above teaching. Further, it should be noted that any or all of theaforementioned alternate implementations may be used in any combinationdesired to form additional hybrid implementations of the presentdisclosure.

1. An apparatus, comprising: one or more lens assemblies; a buildplatform gantry; a build platform positioned under the build platformgantry; a plurality of mirrors comprising a precursor mirror, anintermediary mirror, and a final mirror configured to direct incidentlight emanating from the one or more lens assemblies to a specificlocation on the build platform; an energy patterning unit configured toprovide a two-dimensional patterned beam; an image relay configured toreceive and direct the two-dimensional patterned beam to the one or morelens assemblies; and wherein the final mirror is mounted on a firstpodium of the build platform gantry which is movable in both of a firstdirection and a second direction perpendicular to the first directionand rotatable about a first axis, wherein the intermediary mirror ismounted on a second podium of a compensation gantry which istranslatable only in the first direction and rotatable about at least asecond axis, wherein the incident light travels a first distance fromthe precursor mirror to the intermediary mirror, wherein the incidentlight travels a second distance from the intermediary mirror to thefinal mirror, and wherein the build platform gantry is configured totranslate the first podium in the first direction and in the seconddirection and to rotate the final mirror about the first axis in orderto direct the two-dimensional patterned beam at different areas of thebuild platform to fabricate a part; wherein the compensation gantry isconfigured to translate the second podium only in the first directionand rotate the intermediary mirror about the second axis to maintain aconstant value of a sum of the first distance and the second distancefor every position of the first podium and a corresponding position ofthe second podium.